Stihl MS 441 C Operating instructions

STIH)
STIHL MS 441 2006-06

1MS 441, MS 441 C
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© ANDREAS STIHL AG & Co. KG, 2006
Contents
1. Introduction 3
2. Safety 4
3. Specifications 5
3.1 Engine 5
3.2 Fuel system 5
3.3 Ignition system 5
3.4 Chain lubrication 5
3.5 Tightening torques 6
4. Troubleshooting 8
4.1 Clutch 8
4.2 Chain drive, chain brake,
chain tensioner 9
4.3 Chain lubrication 11
4.4 Rewind starter 12
4.5 Ignition system 13
4.6 Carburetor 15
4.7 Engine 18
5. Saw chain /
chain guide 19
6. Clutch 19
6.1 Clutch drum 21
7. Checking operation
of chain brake 23
7.1 Brake band, removal
and installation 23
7.2 Brake lever 25
7.3 QuickStop Super
brake lever 27
7.3.1 Adjusting brake cable 30
7.3.2 Brake cable, removal
and installation 31
7.4 Cam lever 33
7.5 Pins 34
7.6 Chain tensioner 35
7.7 Bar mounting studs 37
8. Engine 37
8.1 Muffler / spark
arresting screen 37
8.2 Leakage testing 39
8.2.1 Preparations 40
8.2.2 Vacuum test 41
8.2.3 Pressure test 41
8.3 Oil seals 42
8.4 Shroud, removal
and installation 44
8.5 Cylinder 45
8.6 Crankshaft 48
8.6.1 Removal 48
8.6.2 Installation 49
8.6.3 Ball bearing /
crankcase 52
8.7 Piston 54
8.7.1 Removal 54
8.7.2 Installation 55
8.8 Piston rings 56
8.9 Decompression valve 57
9. Ignition system 57
9.1 Ignition module 58
9.1.1 Removal and
installation 58
9.2 Ignition timing 60
9.3 Testing the ignition
module 60
9.4 Spark plug boot /
ignition lead 61
9.5 Flywheel 63
9.6 Short circuit wire 64
9.6.1 Testing 64
9.6.2 Removal and
installation 64
9.6.3 Ground wire 66
9.7 Pre-separator 67
9.8 Troubleshooting chart,
ignition system 69
10. Rewind starter 72
10.1 General 72
10.2 Removal and
installation 72
10.3 Pawls 73
10.4 Rope rotor 73
10.5 Starter rope / grip 74
10.6 Tensioning the rewind
spring 75
10.7 Rewind spring 76
10.8 Starter rope guide
bushing 77
11. Anti-vibration system,
repair 78
11.1 Annular buffers 78
11.2 Anti-vibration spring,
front handle 79
11.3 Anti-vibration spring,
fuel tank 79
11.3.1 Anti-vibration spring,
oil tank 80
11.4 Stop buffers 80
11.5 Front handle 81
11.5.1 Front handle with
handle heating 83
12. Actuating levers 84
12.1 Switch shaft 84
12.1.1 Removal and
installation 84
12.2 Throttle trigger / throttle
trigger interlock 85
12.3 Throttle trigger /
throttle trigger interlock /
QuickStop Super 87
12.3.1 Switch lever 89
12.3.2 Throttle trigger
interlock 90
13. Chain lubrication 91
13.1 Pick-up body 91
13.2 Oil suction hose 91
13.3 Oil pump 92
13.3.1 Repair 93
13.3.2 Adjustment 94
13.4 Valve 94
13.5 Oil tank cap 95

2MS 441, MS 441 C
Contents
14. Fuel system 95
14.1 Air filter 95
14.1.1 Baffle 96
14.1.2 Filter base 96
14.2 Spacer flange 98
14.3 Carburetor removal
and installation 99
14.3.1 Leakage testing 100
14.4 Carburetor repair 100
14.4.1 Air flap 100
14.4.2 Metering diaphragm 101
14.4.3 Inlet needle 102
14.4.4 Fixed jet 103
14.4.5 Pump diaphragm 104
14.4.6 Choke shaft /
choke shutter 105
14.4.7 Throttle shaft /
throttle shutter 107
14.4.8 Accelerator pump 109
14.4.9 Adjusting screws 109
14.5 Carburetor
adjustment 111
14.5.1 Basic setting 111
14.5.2 Standard setting 112
14.6 Throttle cable 113
14.6.1 Carburetor support 114
14.6.2 Carburetor housing 116
14.6.3 Intake elbow, removal
and installation 119
14.6.4 Impulse hose 119
14.7 Tank vent 120
14.7.1 Check 120
14.7.2 Removal and
installation 121
14.8 Fuel intake 121
14.8.1 Pick-up body 121
14.8.2 Fuel hoses 122
14.8.3 Fuel filler cap 123
14.8.4 Tank housing, removal
and installation 124
15. Heating 124
15.1 Carburetor heating 124
15.2 Troubleshooting chart,
carburetor heating
element 128
15.3 Handle heating
systems 129
15.3.1 Troubleshooting 129
15.4 Heating switch, removal
and installation 130
15.5 Heating element in
handle, removal and
installation 131
15.6 Heating element in
front handle, removal
and installation 131
15.7 Generator, removal
and installation 131
15.7.1 Troubleshooting chart,
handle heating systems
and generator 133
15.7.2 Summary of test
connections and test
values 135
15.8 Wiring harness 137
15.8.1 Removal 137
15.8.2 Installation 138
16. Special tools 141
17. Servicing
accessories 143

3MS 441, MS 441 C
This service manual contains
detailed descriptions of all the
typical repair and servicing
procedures for this power tool.
You should make use of the
illustrated parts lists while carrying
out repair work. They show the
installed positions and sequence of
steps for the individual components
and assemblies.
Always refer to the latest edition of
the relevant parts list to check the
part numbers of any replacement
parts.
A fault on the machine may have
several causes. To help locate the
fault, consult the chapter on
"Troubleshooting" and the "STIHL
Service Training System" for all
functional groups.
Refer to the Technical Information
bulletins for engineering changes
which have been introduced since
publication of this service manual.
Technical information bulletins also
supplement the parts list and
service manual until an updated
edition is issued.
The special tools mentioned in the
descriptions are listed in the chapter
"Special Tools" of this manual. Use
the part numbers to identify the
tools in the "STIHL Tools" manual
which lists all the tools currently
available from STIHL.
Symbols are included in the text and
pictures for greater clarity. The
meanings are as follows:
In the descriptions:
:= Action to be taken as shown
in the illustration
(above the text)
– = Action to be taken that is
not shown in the illustration
(above the text)
In the illustrations:
APointer (short)
aDirection of movement (long)
b4.2 = Reference to another
chapter, i.e. chapter 4.2
in this example.
Service manuals and technical
information bulletins are intended
exclusively for the use of properly
equipped repair shops. They must
not be passed to third parties.
Servicing and repairs are made
considerably easier by mounting the
machine on assembly stand (3)
5910 890 3100. For this purpose,
secure the clamping rail (2)
5910 850 1650 to the assembly
stand with two screws (1) and
washers.
1
2
3
219RA000 TG
The screws must not protrude,
as they may damage the housings
when clamping the machine,
depending on the model.
1. Introduction

4MS 441, MS 441 C
The flange bolts on the chainsaw
are guided through the outer holes
in the clamping rail and secured
with the nuts (arrows).
The sprocket wheel cover, bar and
chain must be removed first. Pull
the hand guard back against the
219RA001 TG
front handle for this purpose.
Always use original STIHL
replacement parts.
They can be identified by the
STIHL part number,
the STIH) logo and
the STIHL parts symbol (
This symbol may appear alone on
small parts.
All local and specific national safety
regulations as well as the safety
precautions and warnings in the
instruction manual must be
observed if the machine is started
up in the course of repairs or
maintenance work.
Gasoline is an extremely flammable
fuel and can be explosive in certain
conditions.
Suitable gloves must be worn
without fail if parts are heated for
assembly/disassembly purposes.
Improper handling may result in
burns or other serious injuries.
Do not bring any fire, flame, spark or
other source of heat near the fuel.
All work with fuel must be performed
outdoors only. Spilled fuel must be
wiped away immediately.
Test for leakages after all work on
the fuel system and engine.
2. Safety

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